Temperature-Regulating Mattress

ABSTRACT

A temperature-regulating mattress system provides dynamic adjustment of temperature and other parameters throughout a user&#39;s sleep cycle to maximize the quality of the user&#39;s sleep, Features of the system may include: (a) heating and cooling temperature regulation (with dynamic custom profiles that control humidity and are dual-zone); (b) smart controls (with remotes and apps that learn from users to optimize settings and work with smart home products such as Alexa and interactive lighting systems); (c) comfort (with a mattress that provide the necessary support for its users); and (d) sensors used for temperature and humidity estimation algorithms, control mechanism, and additional inferences from those sensors (pose, enrichment of biometric sensing data, etc.).

REFERENCE TO PRIOR APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.16/390,194 filed on Apr. 22, 2019, which itself claims the benefit of:

1) U.S. Provisional Application Ser. No. 62/661,623 filed on Apr. 23,2018;

2) U.S. Provisional Application Ser. No. 62/686,653 filed on Jun. 18,2018;

3) U.S. Provisional Application Ser. No. 62/738,782 filed on Sep. 28,2018;

4) U.S. Provisional Application Ser. No. 62/753,032 filed on Oct. 30,2018; and

5) U.S. Provisional Application Ser. No. 62/808,299 filed on Feb. 21,2019;

This application also claims the benefit of U.S. Provisional ApplicationSer. No. 62/966,018 filed on Jan. 26, 2020, and of U.S. ProvisionalApplication Ser. No. 62/993,687 filed on Mar. 23, 2020. Each of theapplications identified above is incorporated by reference herein in itsentirety.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to an improved mattress systemwith an ability to provide a dynamic responsive environment for its useror users.

BACKGROUND

The majority of people experience disruptions to their sleep due totemperature problems at least a few nights a month. Existing solutions(such as air conditioning, ceiling fans, room heaters, open windows andthe like) are not effective for temperature regulation during sleep.There is therefore a need for an improved method to provide acomfortable sleeping experience by dynamically maintaining the propertemperature during the sleep cycle.

SUMMARY

A temperature-regulating mattress system provides dynamic adjustment oftemperature throughout a user's sleep cycle to maximize the quality ofthe user's sleep, Features of the system may include: (a) heating andcooling temperature regulation (with dynamic custom profiles thatcontrol humidity and are dual-zone); (b) smart controls (with remotesand apps that learn from users to optimize settings and work with smarthome products such as Alexa and interactive lighting systems); (c)comfort (with a mattress that provide the necessary support for itsusers); and (d) sensors used for temperature and humidity estimationalgorithms, control mechanism, and additional inferences from thosesensors (pose, enrichment of biometric sensing data, etc.).

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, where like reference numerals refer toidentical or functionally similar elements throughout the separateviews, together with the detailed description below, are incorporated inand form part of the specification, and serve to further illustrateembodiments of concepts that include the claimed invention and explainvarious principles and advantages of those embodiments.

FIG. 1A shows a functional diagram of the temperature-regulatingmattress system.

FIG. 1B shows a block diagram of the temperature-regulating mattresssystem.

FIG. 2 shows a thermal diagram of the temperature-regulating mattresssystem.

FIG. 3 shows a temperature-regulating mattress system having integratedsensors.

FIG. 4A shows a wireless communication path diagram of atemperature-regulating mattress system.

FIG. 4B shows a wireless communication path diagram of an appcontrolling a mattress system.

FIGS. 5, 6, 7 and 8 show exploded views of a temperature-regulatingmattress system.

FIGS. 9,10 and 11 show cross-sections of a temperature-regulatingmattress system.

FIG. 12 shows a schematic of a sensor.

FIG. 13 shows a cross-section of a temperature-regulating mattresssystem with integrated sensors.

FIG. 14 shows sensors embedded in a comfort layer.

FIG. 15 shows sensors embedded in tethered layers.

FIG. 16 shows sensors embedded in a mattress cover.

FIG. 17 shows assembly of a cover over a mattress system.

FIG. 18A shows an exploded view of a mattress cover.

FIG. 18B shows an exploded view of a base cover.

FIG. 19 shows a detailed view of a seams within the mattress cover andbase cover.

FIG. 20 shows further detail of the bottom cover of atemperature-regulating mattress system.

FIGS. 21 and 22 show schematics of an integrated mattress base.

FIGS. 23, 24A and 24B show schematics of a modular mattress base.

FIGS. 25 and 26 show schematics of a mattress base layer.

FIG. 27 shows internal wiring of a base layer.

FIG. 28 shows external wiring of a base layer.

FIGS. 29A and 29B show schematics of an adjustable base layer.

FIGS. 29C and 29D show hinges in an adjustable base layer.

FIG. 29E shows a folded base layer.

FIGS. 30A, 30B, 31 and 32 show schematics of an integrated airbox.

FIGS. 33A, 33B, 34 and 35 show schematics of a modular airbox.

FIG. 36 shows a cross-section of a mattress system showing air deliverychannels.

FIGS. 37 and 38 show a schematic of air distribution patterns in amattress system.

FIGS. 39A, 39B, 39C, 39D, 39E and 39F show various methods for sealingsurface of holes or slots in a mattress.

FIGS. 40A, 40B and 40C show configurations to improve airflow in amattress system.

FIG. 41A shows a schematic of a remote for a mattress system.

FIG. 41B shows a cross-section and FIG. 41C shows an exploded views ofthe remote in FIG. 41A.

FIGS. 42, 43, 44 and 45 show schematics of alternative remotes formattress system.

FIGS. 46A, 46B, and 46C show various additional embodiments of holes orslots in a mattress.

FIGS. 47A and 47B show various additional embodiments of holes or slotsin a mattress.

FIGS. 48A and 48B show various additional embodiments of holes or slotsin a mattress.

FIGS. 49A and 49B show various additional embodiments of holes or slotsin a mattress.

FIGS. 50A and 50B show various additional embodiments of holes or slotsin a mattress.

FIG. 51 shows views of a mattress system using inserts with holes orslots.

FIGS. 52A, 52B, 52C, 52D, 52E, and 52F show various embodiments of theinserts in FIG. 51.

FIG. 53 shows another embodiment of a mattress system using inserts withholes or slots.

FIG. 54 shows an embodiment of a mattress system using inserts forforming holes or slots.

FIG. 55 shows another embodiment of a mattress system with holes orslots.

FIG. 56 shows another embodiment of a mattress system with holes orslots.

FIGS. 57A, 57B, 57C, and 57D show an embodiment of a seven-layermattress system that uses tubular inserts.

FIGS. 58A, 58B, and 58C show cross-sectional views of another set ofembodiments of a mattress system with holes or slots.

FIGS. 59A, 59B, and 59C show cross-sectional views of another set ofembodiments of a mattress system using molded insert.

FIGS. 60A and 60B show cross-sectional views of a set of embodiments ofa mattress system using die cut inserts.

FIGS. 61A, 61B, and 61C show cross-sectional views of a set of mattresssystem embodiments having drilled holes.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present invention.

The apparatus and method components have been represented whereappropriate by conventional symbols in the drawings, showing only thosespecific details that are pertinent to understanding the embodiments ofthe present invention so as not to obscure the disclosure with detailsthat will be clear to those of ordinary skill in the art having thebenefit of the description herein.

DETAILED DESCRIPTION I. Introduction

Devices and algorithm for determining and controlling temperatureexperienced by users under blankets in bedding may be deployed. Sensorspositioned at the mattress surface are used in conjunction with acontrols model for bedding to estimate and control user experiencedtemperature, humidity, and position on the bed. This includes devicesbeing used for temperature and humidity estimation algorithms, controlmechanism, and additional inferences from those sensors (pose,enrichment of biometric sensing data).

A variety of approaches may be used to sense temperature, humidity, andbody pose at the surface of a mattress. Considered here are wirelesssurface sensors, as well as wired sensors and smart fabrics. A wirelesssurface sensor consists of a battery, antenna, temperature and humiditysensors, and a capacitive sensor. The surface sensor measurestemperature and humidity using sensor mounted under metal grill. It usesthe metal of the grill for capacitive sensing of human presence abovethe sensor, as well as for improved thermal contact to the sensedenvironment. It broadcasts temperature, humidity, capacitive presence(sensor payload) to controller at regular interval.

Surface sensors may be placed on a mattress or in holes on surface ofmattress under mattress cover and fitted sheet.

Surface temperature, humidity, or presence sensors may also beimplemented as a wired solution, or with smart fabrics.

A temperature control unit receives data (wired or wirelessly) fromsurface sensors, as well as from sensors measuring ambient airtemperature and humidity. Based on this data received, the temperaturecontrol unit can control the amount and temperature of air added to theuser's experienced temperature (blanket microclimate). The technologycould apply to other methods of heating user's experienced temperature,including heated fabrics or foam.

Temperature and humidity directly measured from the surface sensordevices is not the same as what the user in the blanket microclimate isexperiencing. Depending on blanket types, how well the blanket coversthe mattress, how much heat or humidity the user is generating, andambient conditions, temperature measured at the mattress surface mayvary as much as 5-7° C. from the user-experienced temperature.

To estimate the user-experienced temperature, a temperature control unitestimates various thermal parameters of the bed. The device maintains amodel of the bedding environment and continuously calibrates itself tobest estimate the value of these various thermal resistances andcapacitances. By estimating the value of these thermal parameters, themodel can maintain an estimate of the user's experienced temperature.The device maintains a state-space model of the mattress and usesparameter identification techniques to estimate bedding parameters.

Mattresses that accommodate two users can incorporate airflow or heatflow across two zones of the mattress into their models for control tocontrol two separate zones of user experienced temperatures.

Processing on data from surface sensors that allows system to estimateuser's poses on the bed, which can be used to inform other algorithmsand enrich other sensing data. The sensor knows when a body is in directcontact and can reject or adjust temperature readings as needed based onthis information.

Smart bed, heating and cooling bed, use with algorithms that canincorporate temperature user experiences in bed, user pose on bed toimprove readings of other signals from users, and for controllingtemperature precisely enough to improve sleep.

The key physics being taking advantage of is that dynamics of the bedthermal system are governed by a set of differential equations withparameters corresponding to the amount of heat added by the user, thethermal resistance of the blanket (such as, is it thick or thin). Sinceit is known what heat is being input to the system from our temperaturecontrol unit, it is possible to use the shape of the heating or coolingcurves measured at the surface sensors to estimate the parameters of thedifferential equations. The differential equation-based model of thesystem may be used to control its temperature.

Based on the model's prediction of the microclimate temperature, thecontrol algorithm adjusts heat and blower parameters to achieve a tightdegree of temperature control (within a degree or so), which is requiredto provide precise comfort profiles through the night that might improvea user's sleep.

The control algorithm is also able to consistently update the parametersit's measuring about the state of the bed through the night to accountfor user's disruption of blankets, introduction of ambient air into themicroclimate, or other changes to the environment that might occurovernight. In this way, the control algorithm is robust to the way theuser sleeps.

The surface sensors also measure humidity. The control algorithmestimates offset between surface measured humidity and user experiencedhumidity, and uses that information to help control humidity to within acomfortable band for the user.

The surface sensors also measure capacitive presence above them. If asleeper is above the surface sensor, the capacitive presence may be usedto reject the temperature measured by this sensor (offset by the user'sbody temperature in this case).

The surface sensor capacitive presence measurements may be used toestimate the pose of the user on the bed. This pose may be used toinform other algorithms in the device. For example, if there is acontactless heart monitoring system operating concurrently with thetemperature and humidity control algorithm, pose sensing on the bedmight help separate two user's heartbeats by assessing what relativestrength of signal to expect from each user at various locations.

Further, devices and algorithm are described herein for introducingtemperature interventions to improve sleep onset, depth, and wakeinertia by measuring biometric signals, including heart rate, breathingrate, brain activity, motion, and/or temperature. Various temperatureinterventions are controlled, in part, by biometric sensors andalgorithms estimating the user's state (for instance core bodytemperature, sleep stage) to provide the optimal temperature at theoptimal time (comfort profile). Over time, the algorithm can learn whatcomfort profiles improve sleep onset, sleep depth, and wake inertia fora particular user.

Smart mattress control user experienced temperature in blanketmicroclimate (possibly with independent control of chest and feet), andmeasures motion, heart rate and respiration rate, amongst otherbiometric signals. Measurements of these various biometric signals canbe through ballistocardiography performed from under-mattress,in-mattress, or in-mattress-cover, or through smart fabrics, wearables,radar, camera, or other sensing mechanisms.

Core body temperature reduction has been shown to be important to theonset and depth of sleep. Sleep stage has been shown to be important tothe body's thermal regulation ability. For instance, during REM sleep,the body isn't able to thermoregulate. Various thermal interventions(changes to user's experienced temperature under the blankets) can beused to manipulate core body temperature and enhance sleep.

The algorithms use biometric sensing data (motion, heart rate, andrespiration rate) to estimate core body temperature and sleep stage.Temperature interventions are adjusted real-time based on the sensor andalgorithm outputs.

By manipulating user's experienced temperature (through foot warming,skin warming, and other temperature profiles), the device can use thesensor and algorithm output to confirm that its temperature therapy ishelping the user drop and maintain a low core body temperature throughthe night. Temperature therapy can be adjusted based on biometricfeedback to do this. Wakes might be predicted by observing motion, heartrate, or sleep stage. Temperature profiles can be adjusted during thenight to prevent those wakes or lull the user back to sleep once theyawake.

Algorithms may control temperature experienced by a user in order toreduce sleep latency (fall asleep faster), stay asleep longer (fewerwakeups), sleep more deeply (more REM+Slow Wave Sleep), and nudge usersinto a shallower phase of sleep in time for their desired wakeup time.

The algorithm may run on an ecosystem of products that provide lighting,temperature, sound, and other therapies to improve sleepdynamically—they respond to sensors that are also distributed in theecosystem. Sensors in the ecosystem measure experienced temperature andhumidity, light exposure, heart rate, respiration rate, and othersignals.

Algorithms can tune lighting, temperature, sound, and other therapiesbased on sleep quality observed from sensed data.

Smart bed, heating and cooling bed, use with algorithms that canincorporate temperature user experiences in bed, Helping normal userswith thermoregulation to help them sleep, helping users with circulationproblems (obesity, diabetes, etc.) and other sleep issues withthermoregulation to help them sleep, use of other ecosystem products(temperature, light, sound control before, during, and after sleep) toimprove sleep with biometric sensing in the mattress as a feedbackmechanism to tailor therapies.

The present devices may use independent temperature control at the torsoand feet through the night to try to improve sleep. A naive temperatureprofile delivered by a control device might provide warmth as the useris falling asleep, cool the user while they're asleep to preventnight-time wakes, and warm the user up before wakeup.

The algorithm uses biometrics data to improve on this naive temperaturecontrol profile. Application of a temperature profile (heating feet, forinstance) is intended to aid the body's normal thermoregulatory processduring the night. This includes cooling down core body temperatureduring sleep onset, maintaining lowered core body temperature throughthe night, and increasing core body temperature before wake.

There is evidence that poor thermoregulation is implicated in poor sleepfor diabetics, the obese, patients who suffer from Raynaud's disorder,and other circulatory and sleep issues. There is evidence that normalsleepers thermoregulatory process can be impacted by food and alcoholconsumption before bed, or by hormonal cycles. Users whosethermoregulatory function is changed may need a temperature interventionto assist in falling asleep, staying asleep and waking up.

This thermoregulatory process can be tracked by watching a user's heartrate. As core body temperature decreases at the beginning of the nightand increases at the end of the night (corresponding to metabolism ratedecrease and increase), heart rate also increases and decreases. Heartrate data can be used to measure the impact of the temperatureintervention and to adjust the temperature accordingly in real time.

Sleep staging data teased out from heart rate, respiration rate, motion,EEG, or eye movement detection can be used to assess quality or depth ofsleep night for night, and use machine learning to optimize sleepingtemperatures per user.

To help users fall asleep, foot warming or other temperature profilesmay be used. In real time, the profiles watch their heart rate to makesure it is dropping as expected (corresponding to core body temperaturedecline).

Once the heart rate, respiration rate, and motion tracker detect thatthe user has fallen asleep, the next phase of temperature therapybegins.

While the user is asleep, the heart rate, respiration rate, and motionare used to predict when a user may wake up during the night. The samefoot warming or other falling-asleep therapy applied to the user to helplull them back to sleep can be used.

Temperature profiles during the night that increase slow wave and REMsleep may be used. The algorithm measures how much slow wave and REMsleep was experienced per night and optimize sleep temperature profilenight for night to increase this deeper sleep.

Finally, the heart rate may be used to track increasing core bodytemperature through full body warming in the time before the user has towake up. The sleep stage is monitored to ensure the user is nudged outof deep or slow wave sleep.

This same concept of tracking heart rate, respiration rate, and motionthrough the night, tying them to core body temperature and sleep stagethrough the night, and tuning interventions like temperature during thenight, can be applied to all products intended to help sleep. Thisincludes light therapy, sound masking, and various mattress and blanketproduct choices (firmness, ergonomics, thermal and humidity performanceof bedding). All of these products can be adjusted to improve sleepdepth and quality, with biometric sensing as a feedback mechanism.

Biometric and other data that might be relevant as a marker for sleepquality (phone use, light exposure, diet, alcohol consumption) can becollected from an ecosystem of sleep sensors, as well. Interventionsfrom a sleep ecosystem could include (in additional to temperature,light, and sound interventions) sleep coaching, diet recommendations,bedding recommendations. In this way a platform for sleep might becreated amongst a wide variety of devices and data sources.

While various embodiments discussed herein show wireless and wiredfunctionality in specific areas, any wired connection may function via awireless connection and vice versa. In addition, any discussion ofBluetooth may include any other wireless protocol (including Wi-Fi),whether existing now or in the future. Further, any Bluetooth (or otherwireless) node shown herein may operate as either a master or slave asappropriate.

In addition, the mattresses discussed herein may be of any size,including without limitation: twin, full, queen, king, California kingand extra-long (of any size).

In addition, for a 2-user mattress, the features described herein may beindependently adjusted to provide different experiences for each user.

Turning to a more detailed description, the various features of thistemperature-regulating mattress may be classified into seven overallcategories: System, Sensor, Cover, Base, Airbox, Airflow and Remote.Each will be discussed in turn.

II. System

The scope and functionality of the temperature-regulating mattresssystem taken in the aggregate is described herein.

Turning to FIG. 1A, shown us a functional diagram of thetemperature-regulating mattress system 100. A legend 112 shows thevarious parts of this system: processor, radio/comms, input/sensor,output/actuator, remote, comfort layer and base layer.

A main board 108 comprises a system microcontroller unit (MCU) thatprovides overall governance of the system and communicates with othercomponents through a Wi-Fi or Bluetooth radio. Two high voltage controlboards 110 (HVCBs) comprise a control MCU that provides governance ofthe control boards and connects to the system MCU. The control MCU alsointerfaces with a plurality of relative humidity (RHT) sensors andcurrent and voltage (I/V) sensing systems associated with either aheater or a fan. Two biometric sensors 102 comprise a biometric sensorand a biometric MCU that provides governance of the biometric sensor andconnects to the system MCU. A plurality of surface sensors 104 comprisea sensors MCU that provides governance of a plurality of RHT sensors andpresence sensors. Two remote systems 106 comprise a remote MCU thatprovides governance of the remote and communicates with the rest of thesystem via a Bluetooth radio. The remote MCU has inputs comprising aproximity sensor, button, rotary encoder and light sensor. The remoteMCU outputs to a haptic actuator and a LED controller that drives LEDs.

Turning to FIG. 1B, shown is a block diagram of thetemperature-regulating mattress system 150. A mattress 156 coordinatesvia Bluetooth with two mobile devices 152 a, 152 b, a cloudplatform/backed 154 and two remotes 158 a, 158 b.

Although these figures show specific numbers of devices and specifictypes of radio communication, any number of devices and radiocommunication types may be used.

Turning to FIG. 2, shown is a thermal model 200 thetemperature-regulating mattress system. At the top of the thermal model200 is the atmosphere 205 followed by the resistance/capacitance a ofblanket 210. This combined with the heat added by a user comprises amicroclimate 240 that sits above the mattress and below the blanket.Additional resistance/capacitance 215 of the cover and fitted sheetbelow the user is associated with a temperature control unit 220(airbox). Surface sensors 230 sit in between the matter and mattresscover.

The capacitor/resistor pair 225 models the thermal relationship betweenthe airbox (temperature control unit 220) and the location of thesurface sensors 230. In other words, how is the temperature of aircoming out of the airbox affecting the temperature at the surfacesensors due to convection/conduction/radiation between them?

The capacitor/resistor pair 235 models the thermal relationship betweenthe temperature in the micro-climate (air under the covers that the useris in) and the temperature at the surface sensors (which are separatedfrom the micro-climate by several layers of fabric, and therefore do notread the micro-climate temperature directly). Determining the parametersfor these interfaces (e.g. how much does the temperature change betweenthe two environments, or in other words how much thermal resistance isthere between them) enables a good estimate of the micro-climatetemperature from the temperature measured at the location of the surfacesensors.

Turning to FIG. 3, shows a temperature-regulating mattress system havingintegrated sensors 300. This comprises a mattress 308 having a hiddenbase layer 310 on the bottom and a transparent mattress cover 311 on thetop. Surface sensors 304 a-304 h and ventilation cuts 306 a-306 d areincorporated within the mattress 308. The surface sensors 304 a-304 hmay include temperature, humidity and user presence sensors that areintegrated into the mattress cover and are designed to be roll-packed.The ventilation cuts 306 a-306 d cut through the comfort layer near thetorso and fee to allow air to distribute through the mattress.

The hidden base layer 310 is hidden by a fabric cap on a comfort layerand may be of any relevant size and shape. The transparent mattresscover 311 may have varying levels of opacity.

Turning to FIG. 4A, shown is a wireless communication path diagram 400of a temperature-regulating mattress system. The mattress 422 is dividedinto two parts, side A 410 a and side B 410 b. Two consoles/remotes/userinput devices 405 a, 405 b communicate with an electronics module 412via Bluetooth. The electronics module 412 communicates through the cloudto wirelessly store and retrieve temperature profiles 450. Theelectronics module 412 may include fans, heaters, coolers, printedcircuit boards and may be removable for servicing.

Based on the input of the console/remotes/user input devices 405 a, 405b and the temperature profiles 450, the electronics module 412interfaces with foot sensor groups 410 a, 410 b and torso sensor groups408 a, 408 b. Each of the sensor groups communicates via Bluetooth withthe appropriate temperature, relative humidity and pressure sensors. Thesensors also may measure movement, presence, heart rate and breathingrate.

Although this FIG. 4A shows a wireless system, one or more portions ofthe system may be wired. Additional sensors may be placed within themattress 422 as warranted. And although the electronics module 412 isshown at the foot of the bed 422, airboxes may be integrated in the footand torso portions of the bed 422 (or other portions).

Turning to FIG. 4B, shown is a wireless communication path diagram of anapp controlling a mattress system 4600. Comfort profile storage 4622interfaces with cloud storage 4650, a remote 4604, an onboarding portal4632 and a feedback portal 4634 and a mattress hub 4630.

The onboarding portal 4632 is designed to collect data about the userbefore the user goes to sleep. The data may include the user's gender,age, weight, sleep pattern, sleep location, desired temperature, desiredrelative humidity and the like. The onboarding portal 4632 may be usedto control sleep parameters through the sleeping process. The remote4604 may also be used during the sleep period to adjust sleep parametersthrough the sleep process. The advantage of the remote 4604 over theoutboarding portal 4632 is that the remote 4604 only requires simpleactions such as a push, twist or gesture to control the sleepparameters. This allows the user to easily and quietly adjust parametersthroughout the sleep period without having to boot up an onboardingportal 4632 on a phone, tablet or other portable device.

At the end of a sleep period, a user may use a feedback portal 4634 toreport on the quality of sleep, the temperature, the humidity and otherparameters during the sleep period. This data is reported to the comfortprofile storage 4622 to update the user profiles as appropriate.

The hub 4630 may also interface wirelessly with sensor groups 4605, 4606having temperature, relative humidity and pressure sensors. The hub 4630may interface with heaters 4612 and fans 4614 in the mattress system andtheir related exhaust temperature and humidity sensors 4610.

Although both onboarding portal 4632 and feedback portal 4634 are shownrouting through cloud, one or both of portals may connect directly to amattress control main board via Bluetooth/Wi-Fi/wireless or wiredconnection.

FIGS. 5, 6, 7 and 8 show exploded views of a temperature-regulatingmattress system.

Turning to FIG. 5, shown is an exploded views of atemperature-regulating mattress system 500. On the left is an unexplodedmattress view. On the right side, an exploded view shows a comfort layer510 on the top, followed by comfort layer stiffness adjusters 512,followed by a base layer 514. The comfort layer stiffness adjusters 512may be flexible structures made from foam, rubber, gel or other flexiblematerials. They may also be air permeable to aid in air distribution.The base may form protrusions from air paths between the mattress andbed frame or foundation.

Sandwiched between the comfort layer 510 and the base layer 514 is anelectronics module 516. The electronics module 516 may include fans,heaters, printed circuit boards and may be removable for servicing.

A side view of a cross-section of a mattress system shows theelectronics module 516 and an air distribution system 518 fordistributing the air throughout the mattress. The system may be eitherincorporated into foam as molded or cut channels or a separately moldedpart that is inserted into a cavity under the comfort layers.

Turning to FIG. 6, shown are various views of a temperature-regulatingmattress system 600. On the left is a complete mattress view 604 a withthe air intake module 606 a jutting out. On the top right, the completemattress view 604 b is shown with the combined electronics module 608 aand air intake module 606 d. This may include fans, heaters, printedcircuit boards and may be removable for servicing.

On the middle right and bottom right shown is a semi-transparentmattress in a perspective view 604 c and side view 604 d with thecombined electronics module 608 b, 608 c and air intake module 606 b,606 c in its place on the bottom of the mattress 604 c, 604 d.

The views also show comfort and diffusion materials 610 a, 610 b alongwith a distribution layer 612 below those materials. The comfort anddiffusion materials 610 a, 610 b may be air permeable materials diffusesand distributes air delivered by the distribution layer 612. Thedistribution layer 612 may be either incorporated into foam as molded orcut channels or a separate part that is inserted into cavity undercomfort layers.

Turning to FIG. 7, shown are various views of a temperature-regulatingmattress system 700. On the left is a complete mattress with a comfortcover top 705 and an air permeable cover top 708. On the bottom shown isthe placement of electronics module 714.

This may include fans, heaters, printed circuit boards and may beremovable for servicing.

On the right shown is the placement of air intake 712 and diffusionmaterials 710 that may be air permeable material that diffuses anddistributes air.

Turning to FIG. 8, shown is a complete mattress exploded view 800. Thetop layer is a cover top 802, followed by a series of comfort layers804, followed by a distribution layer 806, followed by an intake layer808 and followed by a cover bottom 812. Installed on the intake layer808 are electronic modules 810 that may include fans, heaters, printedcircuit boards and may be removable for servicing.

The cover top 802 may be comfortable and air permeable. The distributionlayer 806 may be either incorporated into foam as molded or cut channelsor, alternatively, be a separate part that is inserted into a cavityunder comfort layers. The intake layer 808 may be about 2 inches inheight and consist of flexible, structural impermeable materials withair channels. The cover bottom 812 may have air permeability and bedurable.

FIGS. 9,10 and 11 show cross-sections of a temperature-regulatingmattress system.

Turning to FIG. 9, shown is a mattress cross-section first embodiment900 consisting of a comfort layer cross-section 901 and a base layercross-section 951. The comfort layer cross-section 901 includes amattress cover top panel 905 over a top panel foam insert 906 that arejoined at a stitch seam 908. On the side is a mattress cover outerborder 910 and a mattress cover inner border 912 that are joined withthe base via a mattress cover to base cover zipper 920. On the top areembedded surface sensors 903 and surface sensor patches 904.

The comfort layer 901 is partially surrounded by a mattress fire sock914. A mattress cover zipper 916 secures a mattress cover base panel 918and a mattress cover to base cover zipper 820. A surface sensor plug 926provides power to the system.

Within the mattress itself are foam comfort layers 924 with an embeddedergonomic gel matrix 922. Cut vertically through the mattress areair-impermeable surfaces 902 for air passage.

The base layer 951 cross-section includes a base top panel 958 and abase cover zipper 960 that secures a base cover border 962. A mattresscover to base cover zipper 966 secures a base cover base panel 968. Onthe top is a biometric sensor 956. On the side is a surface sensorsocket 952. On the bottom is an AC power socket 972 and AC power cord970.

Across the base layer cross-section 951 are a series of expandedpolypropylene (EPP) segments 976. A torso airbox 974 and feet air box984 are integrated within the EPP segments 976. Each airbox includes afan 978 a, 978 b and a heater 980 a, 980 b. Air ducts 982 a, 982 b allowair to circulate throughout the height of the base layer 951.

The EPP Segments 976 shown in this figure and elsewhere in theapplication consist of expanded polypropylene chosen because of itslightweight and strong properties. It may be easily molded in variousshapes including molding including nuts that for screws to be insertedthereto. These segments may also comprise expanded polyethylene (EPE)expanded polystyrene (EPS) and be injection molded, blow molded,rotationally molded, pressure formed or vacuum formed.

Turning to FIG. 10, shown is a mattress cross-section second embodiment1000 consisting of a comfort layer cross-section 1001 and a base layercross-section 1051. The comfort layer cross-section 1001 includes amattress cover outer top panel 1005 over a top panel foam insert 1007that are joined at a stitch seam 1008. On the side is a mattress coverouter border 1011 and a mattress cover inner border 1012 held togetherby an inner cover to outer cover snap 1010. The mattress cover innerborder 1012 is also the mattress cover inner top panel 1006 at the topof the mattress.

On the top are embedded surface sensors 1003 and surface sensor patches1004.

The comfort layer 1001 is partially surrounded by a mattress fire sock1014. A mattress cover zipper 1016 secures a mattress cover base panel1018 and a mattress cover to base cover zipper 1020. A surface sensorplug 1026 provides power to the system.

Within the mattress itself are foam comfort layers 1024 with an embeddedergonomic gel matrix 1022. Cut vertically through the mattress areair-impermeable surfaces 1002 for air passage.

The base layer 1051 cross-section includes a base top panel 1058 and abase cover zipper 1060 that secures a base cover border 1062. A mattresscover to base cover zipper 1066 secures a base cover base panel 1068. Onthe top is a biometric sensor 1056. On the side is a surface sensorsocket 1052. On the bottom is an AC power socket 1072 and AC power cord1070.

Across the base layer cross-section 1051 are a series of expandedpolypropylene (EPP) segments 1076. A torso airbox 1074 and torso air box1084 are integrated within the EPP segments 1076. Each airbox includes afan 1078 a, 1078 b and a heater 1080 a, 1080 b. Air ducts 1082 a, 1082 ballow air to circulate throughout the height of the base layer 1051.

Turning to FIG. 11, shown is a mattress cross-section third embodiment1100 consisting of a comfort layer 1101 cross-section, an airbox layer1106 cross-section, an intake layer 1103 cross-section and an adjustablebase 1104 cross-section. The adjustable base may be folded about thegaps shown.

The comfort layer 1101 may be about 11.5 inches comprises a plurality oftemperature, humidity, motion sensors 1102 a-1102 e below the mattresscover and is surrounded by a comfort layer fire sock 1122. On the top isa comfort layer cover 1120 and within are comfort foam layers 1124.Vertical sealed inside surfaces 1110 allow for air distribution throughthe comfort layer 1101 while prevented lateral airflow.

The airbox layer 1106 may be 2 inches and includes a biometric sensor1112, and 2 airboxes 1130 a, 1130 b (one torso, one foot, each having aheater and fan that are not shown) surrounded by an airbox chassis 1128a, 1128 b. The biometric sensor 1112 may measure heart rate, breathingrate and presence sensing.

Between each airbox chassis 1128, 1128 b and the airbox cover 1126 a,1126 b is thermoformed foam 1118 a, 1118 b. Also incorporated aretemperature and humidity sensor downstream of the heater 1114 a, 1114 band temperature and humidity sensor upstream of the fan 1116 a, 1116 b.

The intake layer 1103 may be about 2 inches comprises intake layer foam1132 and surrounded by an intake layer fire sock 1134.

III. Sensors

The scope and functionality of sensors within a temperature-regulatingmattress system is described herein. Such sensors may measure one ormore of the following: temperature, (relative) humidity,pressure/presence, movement, presence, heart rate, breathing rate andother biometric parameters.

Turning to FIG. 12, shown is a schematic of a wireless sensor system1200. Within the system, there is a metal grille 1205 over electronicsfor temperature and humidity sensing 1210 powered by a battery 1220. Thesensor system 1200 communicates wirelessly via an antenna 1230.

Turning to FIG. 13, shown is a cross-section of a temperature-regulatingmattress system 1300 with various integrated or embedded sensors.

A user lies on the mattress 1340 along the dashed line 1325 with bedding1310 above and a sheet 1330 and mattress protector 1335 below. Sensorsmay be integrated or embedded in all parts of the system, including atfoot sensor 1320, a top-of-sheet sensor 1345, an under-sheet sensor 1350and an embedded sensor 1355. Single or multiple sensors per user may beused.

Turning to FIG. 14, shown are sensors embedded in a comfort layermattress system 1400.

A series of sensors are wired into comfort layer at the foot 1410 a andthe torso 1410 b. Wires 1420 run through the mattress system 1400 thatare installed in the comfort layer before the cover is installed. Thewires 1420 then are directed to a connector 1430 that interfaces withthe base 1440. The power of the base layer 1440 may also power thesensors 1410 a, 1410 b via the connector 1430 and wires 1420.

Turning to FIG. 15, shown are sensors embedded in tethered layersmattress system 1500. A sensor band 1510 wraps around a comfort layer1515 and is secured 1520 to the base layer 1525. The sensor band 1510may include multiple sensors of various functions and includes anelectric connection when secured 1520 so that the power of the baselayer 1525 may also power the sensor band 1510.

The sensor band 1510 is covered with sheeting by the user.

There may also be wider bands or multiple bands in this system. Or theband footprint may extend to any part of the mattress and have multiplecutouts.

Turning to FIG. 16, shown are sensors embedded in a cover mattresssystem 1600.

A series of sensors are wired into the cover layer 1615 at the foot 1610a and the torso 1610 b. The cover layer 1615 is designed to be placedover the comfort layer 1640. Wires 1650 run through the cover layer1615. The wires 1615 are directed to a connector wire 1620 thatterminates at a snap connector 1623 that interfaces with the base 1625.The power of the base layer 1625 may also power the sensors 1610 a, 1610b via the connector 1620 and wires 1650.

IV. Cover

The scope and functionality of covers within a temperature-regulatingmattress system is described herein. The cover may consist of anysuitable materials, including latex, memory foam, polyester blends,feathers, wool, cotton, flannel, silk and bamboo. Connecting systemssuch as zippers may be replaced by any other connector such hook andloop fasteners (Velcro®), snaps, tape and the like.

Turning to FIG. 17, shown is an assembly of a cover over a mattresssystem 1700. A mattress core 1710 is shown separated from a base 1720.After being zipped, an assembled mattress core plus base 1730 is shown.

Turning to FIG. 18A, shown is an exploded view 1800 of a mattress cover.Shown staring from the top is a top panel 1802, a foam insert 1804, aninner border 1806, a bottom panel 1808 and an outer border 1810

Turning to FIG. 18B, shown shows an exploded view 1850 of a base cover.Shown starting from the top is a top panel 1852, a border 1854 and abottom panel 1856.

Turning to FIG. 19, shown is a detailed view of a seams within amattress system 1900 with a cover mattress layer 1990 having lowerzipper teeth 1985 and a cover base layer 1992 having upper zipper teeth1983.

On the top shown is a mattress cover outer border 1902 and a mattresscover inner border 1906. In the top inset shown is a mattress cover toppanel 1908, an optional top panel foam insert 1910, a mattress coverouter border 1902 and a mattress cover inner border 1906 all joinedtogether by stitching 1930.

On the bottom shown is a base cover border 1904. In the bottom insetshown is a mattress cover outer border 1902 and an interchangeablereverse coil zipper 1980 a joined together by stitching 1957. Also shownis a base cover mesh fabric 1960 and an interchangeable reverse coilzipper 1980 b joined together by stitching 1955. Also shown is lowerzipper teeth 1985 and upper zipper teeth 1983 joined together bystitching 1956 and zipper 1975. This zipper 1975 is designed to join thecover mattress layer 1990 and a cover base layer 1992.

Turning to FIG. 20 shown is further detail of the bottom cover of atemperature-regulating mattress system. On left side, shown is a spacerfabric sample 1 2050, a spacer fabric sample 2 2054, a fabric diagram2052 and a spacer fabric sample 3 2056. The fabric diagram 2502 shows afront surface, a back surface and spacer yarn in between the frontsurface and back surface.

On the right side, shown is a mattress cross section detail system 2000.Shown is a cover top 2010 that may be comfortable and air permeable anda cover bottom 2025. The cover top 2010 and cover bottom 2025 surroundcomfort layers 2015 (that may be about 10 inches in height) and anintake layer 2020. The intake layer 2020 may be about 2 inches in heightand have a flexible impermeable structure with air channels on theperimeter side 2060 a and bottom 2060 b, 2060 c, 2060 d, 2060 e.

Airflow through the air channels 2060 a, 2060 b, 2060 c, 2060 d, 2060 eare enabled because the cover bottom 2025 may be constructed from spacerfabric or similar material (as shown on the left side of FIG. 20). Thisfabric allows air to move freely through the cover bottom 2025 in boththe perpendicular and parallel directions. In particular, airflow movesthrough the fabric parallel to the surface when the underside andvertical sides of the mattress are blocked by bedframe and bedding.

V. Base

The scope and functionality of bases within a temperature-regulatingmattress system is described herein. The base may include componentsintegrated within the base structure or modular components affixed tothe base structure (or a combination of the two).

FIGS. 21 and 22 show schematics of an integrated base.

FIG. 21 shows a schematic of an integrated base 2100 have a mattress2110 and a base 2120 powered by wire 2140. Air distribution may takeplace in the mattress 2110. Biometric sensors 2130 may be integratedwithin the base 2120. Such sensors may include hear rate/breathingrate/presence sensing and other biometrics.

Also shown is an integrated torso module 2150 a and an integrated footmodule 2150 b. These modules 2150 a, 2150 b may jut out from base 2120because of the airboxes contained therein or may be level with the base2120. The base 2120 may include electronics, fans, heaters and airintake apparatuses.

Turning to FIG. 22, shown is a base system detail 2200 with foam panels2210, a fabric hinge 2220, thermoformed foam 2230 and permeable fabrics2240 a, 2240 b. As will be shown below, the fabric hinge will allow thebase 2120 to be folded in various combinations.

FIGS. 23, 24A and 24B show schematics of a modular base.

Turning to FIG. 23, shown is a schematic of a modular base system 2300.

Temperature, humidity and motion sensors 2302 a-2302 f are incorporatedbelow the mattress cover within the mattress 2306. Modules 2304 a, 2304b (each of which is split into 2 parts) that at least contain airboxes(not shown) are installed on the base 2310.

Biometric sensors 2308 may be integrated within the base 2310. Suchsensors may include hear rate/breathing rate/presence sensing and otherbiometrics.

The modules 2304 a, 2304 b are normally assembled by the end user andconnected to the base 2310 electrically. This may produce betterpackaging solutions with smaller boxes.

Turning to FIG. 24A, shown is a modular base system detail 2400 withoutthe module installed. Shown is a permeable fabric 2420 and athermoformed tray 2430 with a power cable storage 2410.

Turning to FIG. 24B, shown is a modular base system detail 2400 with themodule 2480 installed. Shown is a permeable fabric 2470 a, 2470 b and apower connection 2460.

The system is designed so that the module 2480 is snapped into athermoformed tray 2430 where the power cable located in the power cablestorage 2410 is connected to the power connection 2460. This providespower to the module 2480. Similar setups for 3 other modules (not shown)may be implemented.

Turning to FIG. 25, shown is a schematic of a base layer with cover2500. The fabric cover 2510 (shown as transparent) may be of anysuitable material that is either opaque, translucent or transparent.This allows the base layer components to be contained in a fabric shell.The fabric cover 2510 may be permeable so as to allow air to bedistributed to holes in the mattress installed above the base layer (notshown). A segmented structure 2530 comprising several segments thatallow the base layer to fold for shipment and flex for compatibilitywith adjustable bases.

Turning to FIG. 26, shown is a schematic of a base layer without a cover2600. A biometric sensor track 2610 is inlaid to measure dynamicsleeping profiles for the mattress user, including measuring breathingrate, heart rate and movement throughout the night. Five rigid panels2650 a, 2650 b, 2650 c, 2650 d, 2650 e are installed over five moldedEPP segments 2640 a, 2640 b, 2640 c, 2640 d, 2640 e. This segmentedstructure comprising several segments allows the base layer to fold forshipment and flex for compatibility with adjustable bases.

A torso airbox system 2602 b is installed within rigid panel 2650 cflush with the top of the base layer. Ramps 2630 c, 2630 d are carvedout of the rigid panel 2650 c to allow for airflow. In the alternative,the torso airbox system 2602 b may include integrated ramps on the leftand right to allow for airflow.

A foot airbox system 2602 a is installed within rigid panel 2650 e flushwith the top of the base layer. Ramps 2630 a, 2630 b are carved out ofthe rigid panel 2650 e to allow for airflow. In the alternative, thefoot airbox system 2602 a may include integrated ramps on the left andright to allow for airflow.

Turning to FIG. 27, shown is an internal wiring schematic of a baselayer 2700. Within the base layer 2700 are a wiring system 2710 thatconnects (among other possible devices) a biometric sensor strip 2720, atorso airbox 2730, a feet airbox 2740 and a surface sensor interconnect2750. The torso airbox 2730 and feet airbox 2740 each include two fanson the side and an electrical component in the middle to controloperation of the airboxes 2730, 2740. The surface sensor interconnect2750 interfaces with other sensors throughout the mattress system toproviding inputs to the airboxes 2730, 2740 and transmit outputs fromthe biometric sensor strip 2720.

Turning to FIG. 28, shown are five external wiring schematics within abase layer.

Schematic 12810 shows a wiring system sourced on the side of the foot ofthe mattress. A top view, side flat view and side folded view are shown.

Schematic 2 2820 shows a wiring system sourced on the bottom of themiddle of the mattress. A top view, side flat view and side folded vieware shown.

Schematic 3 2830 shows a wiring system sourced on the top of the middleof the mattress. A top view, side flat view and side folded view areshown.

Schematic 4 2840 shows a wiring system sourced on the bottom of the headof the mattress. A top view, side flat view and side folded view areshown.

Schematic 5 2850 shows a wiring system sourced on the top of the head ofthe mattress. A top view, side flat view and side folded view are shown.

The foregoing schemes may be adjusted such that the wiring is sourced atany other position within the mattress.

Turning to FIG. 29A, shown are various schematics of an adjustable baselayer and its associated mattress. Making the base layer adjustableallows the mattress system to be formed into various configurations foradditional user comfort and for easier shipping.

On the top left, shown is an articulating mattress system 2910 with foursegments in the base layer to allow for such articulation. On the bottomleft, shown is an internal view of the same articulating mattress system2920 with four segments: head (the widest segment), torso (including anairbox), legs and feet (including an airbox). On the top right, shown isan overhead schematic view of the same articulating mattress system 2930with the same four segments. On the bottom right, the same articulatingmattress system 2940 with the same four segments is set in an exemplaryconfiguration. Here, the head segment is set at a 116-degree angle fromthe torso segment, the torso segment is set at a 142-degree angle fromthe legs section and the legs section is set at a 142-degree angle fromthe feet section.

The foregoing system may have a different number of layers capable ofbeing articulated in angles ranging from above 0 degrees to 180 degrees.

Turning to FIG. 29B, shown is a partially exploded view of schematic ofa base of an articulating mattress system 2950. The schematic shows fivesegments joined together with sixteen hinges 2975 shown in an explodedview. The first, second and fourth segments 2942 a, 2942 b, 2942 cinclude no visible electronic parts. The third segment 2951 a includesan integrated torso airbox system 2947 a and the fifth segment 2951 bincludes an integrated feet airbox system 2947 b. The entire system ispowered via a power cord 2971 and an internal wiring system (not shown).

Turning to FIG. 29C, shown is a detail view of an adjustable base layerhinge 2990. On the left side, an overhead view shows the hinge 2975(which may be the same hinge as in FIG. 29B) joining two segments 2924a, 2924 b together. The cross section of hinge 2975 and the two segments2924 a, 2924 b at line A-A is shown on the right side. Here it can beseen that the hinge 2975 flexibly joins the two segments 2924 a, 2924 bbecause the hinge 2975 includes two circular protrusions 2976 a, 2976 bthat snap into two circular receptacles 2980 a, 2980 b. The circularreceptables 2980 a, 2980 b may be carved out of the material thatcomprises the two segments 2924 a, 2924 b such that the circularprotrusions 2976 a, 2976 b remain ensconced in the two segments 2924 a,2924 b at any angle the two segments 2924 a, 2924 b may be set. Theseangles may include those shown in FIG. 29A.

Turning to FIG. 29D, shown is a detail view of another adjustable baselayer hinge. A side view 2901 shows a double hinge 2904 a, 2904 bensconced within two segments 2903 a, 2903 b. A top view 2902 shows thesame double hinge 2904 a, 2904 b ensconced within two segments 2903 a,2903 b. The advantage of this embodiment is that the hinge structure isreinforced in both directions so that flexibility of the two segments2903 a, 2903 b to bend in both directions is enhanced.

Turning to FIG. 29E, shown is a foldable base layer system 2991. Afolded base layer 2995 shows five segments folded on top of one anotheron a bed frame 2993. The folded nature of these five segments may beaccomplished by using the hinges shown in either FIG. 29C or 29D.

VI. Airbox

The scope and functionality of airboxes within a temperature-regulatingmattress system is described herein. The airboxes may include componentsintegrated within the base structure or modular components affixed tothe base structure (or a combination of the two).

The general function of an airbox in the base layer is the selective useof a fan and a heater to generate heated air or cooled air that will beforcefully blown into areas of the mattress installed above the baselayer. Although positive temperature coefficient (PTC) heaters are shownin this section, any suitable convection heater or thermoelectric heatermay be substituted.

In addition, an airbox may be used without the heater for delivery ofair at the ambient air temperature. In addition, an airbox may be usedwith a cooler for delivery air cooler than the ambient air temperature.In addition, an airbox may be coupled with a humidifier or dehumidifierto adjust the relative humidity of the delivered air.

In general, airboxes may be installed in the center of the base layer(to provide air to the torso area of a mattress user) and at the bottomof the base layer (to provide air to the feet area of a mattress user).

FIGS. 30A, 30B, 31 and 32 show schematics of an airbox that isintegrated into the base layer.

Turning to FIG. 30A, shown is top view of an integrated airbox 3000 withair exhausts 3002 a, 3002 b that may output warmed air. The air exhausts3002 a, 3002 b include ramps that allow for enhanced air distribution tothe rest of the mattress.

Turning to FIG. 30B, shown is bottom view of an integrated airbox 3050with air inlets 3004 a, 3004 b. The air inlets 3004 a, 3004 b may drawambient air for possible heating and further distribution with themattress system.

Turning to FIG. 31, shown is a cross-section view of an integratedairbox 3100. The ducting/enclosure top 3105 covers a first blower 3110 aand a PTC heater 3115 a pair and a second blower 3110 b and a PTC heaterpair 3115 b, both of which are installed on an enclosure bottom 3125.Also included is logic board and wiring 3120 that controls the power andoperation of each of the blower/PTC heater pairs 3110 a, 3115 a, 3110 b,3115 b.

Turning to FIG. 32, shown is an integrated airbox system 3200. Intakeairflow 3245 enters a blower 3220, proceeds to a heater 3210 and then isoutputted via lateral airflow 3250 and upward airflow 3260. Downstreamsensors 3230 and upstream sensors 3240 may measure temperature andhumidity of the passing air (where downstream and upstream meansdownstream and upstream from the blower 3220 and heater 3210). This datacan be passed to the rest of the mattress system to keep the mattressenvironment comfortable for the user.

FIGS. 33A, 33B, 34 and 35 show schematics of a modular airbox that isaffixed to the base layer.

Turning to FIG. 33A, shown is top view of a modular airbox 3300 with airexhausts 3310 a, 3310 b that may output warmed air.

Turning to FIG. 33B, shown is bottom view of a modular airbox 3350 withair inlets 3355 a, 3355 b. The air inlets 3355 a, 3355 b may drawambient air for possible heating and further distribution with themattress system.

Turning to FIG. 34, shown is an exploded view of a modular airbox 3400.The exterior comprises a ducting/enclosure mounting frame 3410, endcaps3405 a, 3405 b and an enclosure 3440. The interior comprises a firstblower 3402 a and a PTC heater 3404 a pair and a second blower 3402 band a PTC heater pair 3404 b and a logic board and wiring 3450 thatcontrols the power and operation of each of the blower/PTC heater pairs3402 a, 3402 b, 3404 a, 3404 b.

Turning to FIG. 35, shown is an integrated airbox system 3500. Intakeairflow 3520 enters a blower 3504, proceeds to a heater 3502 and then isoutputted via lateral airflow 3510 and upward airflow 3530 though theholes on top of the airbox. Downstream sensors 3550 and upstream sensors3560 may measure temperature and humidity of the passing air (wheredownstream and upstream means downstream and upstream from the blower3504 and heater 3502). This data can be passed to the rest of themattress system to keep the mattress environment comfortable for theuser.

Turning to FIG. 36 shows a cross-section of a mattress system 3600having air delivery channels. Here, the air entry 3630 passes throughholes in the base or through a vertical perimeter or through body ofspacer fabric. The air then passes through the electronics module 3640.The outputted air passes through distribution ducts 3610 then exits themattress via a series of vertical exhausts 3620. The volume of thedistribution ducts 3610 may vary along its length to affect airdistribution patterns across the surface area of the mattress. Theelectronics module 3640 may include a blower, heater and sensors on oneor more printed circuit boards (PCBs). There may be two or moreelectronics modules 3640 in the mattress system 3600. The electronicsmodule 3640 may be removable for servicing and upgrades.

FIGS. 37 and 38 show different air distribution patterns for air exitinga mattress. Turning to FIG. 37, shown is a schematic of air distributionpatterns in a mattress system 3710 that primarily provide torso and feetairflow through the mattress top. Turning to FIG. 38, shown is aschematic of air distribution patterns in a mattress system 3720 thatprimarily provides airflow throughout the entirety of the mattress top.

VII. Airflow

The scope and functionality of devices that improve airflow within atemperature-regulating mattress system is described herein.

FIGS. 39A, 39B, 39C, 39D, 39E and 39F show various methods for sealingsurface of holes or slots in a mattress cut through the foam comfortlayers. Sealed holes prevent the fluid flow horizontally into the foamthrough the walls of the cutout or from the underside. These methods maybe combined in a mattress system. (The pointers in FIGS. 39A-39F areshown on the right side of the slots, they may equally apply to the leftside of the slots.)

Turning to FIG. 39A (liquid sealant solution), shown is a sealant system3900 with foam comfort layers 3902 adjacent to dried sealant on the side3904 a and bottom 3904 b. These sealants dry to form an impermeable skin(made from, for example, gel, silicon, rubber or adhesive). The sealantmay be poured in the hole or sprayed using a nozzle.

Turning to FIG. 39B (molded/self-skinning solution), shown is a sealantsystem 3910 with foam comfort layers 3912 adjacent to an impermeablefoam on the side 3914 a and bottom 3914 b. Here the, impermeable foammay be created in the hole by the comfort foam layers 3912 pouredsequentially into the mold. The surfaces touching the side and bottomself-skin creating an impermeable surface.

Turning to FIG. 39C (molded/insert), shown is a sealant system 3920 withfoam comfort layers 3922 adjacent to a single impermeable foam insert3924. Here the, impermeable foam insert 3924 may be molded fromself-skinning or a pneumatic foam is assembled into the comfort layers3922 using adhesive.

Turning to FIG. 39D (flexible insert), shown is a sealant system 3930with foam comfort layers 3932 adjacent to a flexible tube 3934. Here athin-walled flexible tube 3934 is inserted into the hole and is heldinto place by friction and/or adhesive. The hole may be expanded duringinsertion to aid in installation. Possible flexible tube 3934 materialsinclude gel, silicone, rubber, latex, polymers or a flexible duct hose.

Turning to FIG. 39E (flexible insert with flange), shown is a sealantsystem 3940 with foam comfort layers 3942 adjacent to a flexible tubewith flange 3944. Here a thin-walled flexible tube with flange 3944 isinserted into the hole and is held into place by friction and/oradhesive. The hole may be expanded during insertion to aid ininstallation. Possible flexible tube with flange 3944 materials includegel, silicone, rubber, latex, polymers or a flexible duct hose. Theflange 3946 adds impermeability to the underside of the mattress.

Turning to FIG. 39F (encapsulated spring insert), shown is a sealantsystem 3950 with foam comfort layers 3952 adjacent to a low stiffnesscoil spring 3954. The low stiffness coil spring 3954 is encapsulated ina sealant such as: an impenetrable polyethylene pocket or sleeve;over-molded rubber; pneumatic foam; or a flexible duct hose. The springholds the hole open while providing minimal vertical stiffness.

Turning to FIG. 46A (flexible insert), shown is a sealant system 4630with foam comfort layers 4632 adjacent to a flexible tube 4634. Here, athin-walled flexible tube 4634 is inserted into the angled hole and isheld into place by friction and/or adhesive. The hole may be expandedduring insertion to aid in installation. Possible flexible tube 4634materials include gel, silicone, rubber, latex, polymers or a flexibleduct hose.

Turning to FIG. 46B (flexible insert with flange), shown is a sealantsystem 4640 with foam comfort layers 4642 adjacent to a flexible tubewith a flange 4644, where the flange portion is identified by referencenumeral 4646. Here, a thin-walled flexible tube with flange 4644 isinserted into the angled hole and is held into place by friction and/oradhesive. The hole may be expanded during insertion to aid ininstallation. Possible flexible tube with flange 4644 materials includegel, silicone, rubber, latex, polymers or a flexible duct hose. Theflange 4646 adds impermeability to the underside of the mattress.

Turning to FIG. 46C (encapsulated spring insert), shown is a sealantsystem 4650 with foam comfort layers 4652 adjacent to a low stiffnesscoil spring 4654. The low stiffness coil spring 4654 is encapsulated ina sealant such as: an impenetrable polyethylene pocket or sleeve;over-molded rubber; pneumatic foam; or a flexible duct hose. Theencapsulated low stiffness coils spring 4654 is inserted into the angledhole. The spring holds the hole open while providing minimal verticalstiffness.

FIGS. 47A and 47B show an additional embodiment of sealed vertical holesor slots in a mattress. Turning to FIG. 47A (sealant, or flexible insertwith a flange and sealant), shown is a sealant system 4740 with foamcomfort layers 4742 adjacent to a sealed vertical hole 4744. The hole4744 is sealed either by a sealant or via an insert as described above.The sealant system 4740 also includes flanges or sealant that extendacross the top and bottom surfaces of the mattress, to extend the sealedareas around the hole(s). In the figure, the bottom flange or sealant isidentified by reference numeral 4746 and the top flange or sealant isidentified by reference numeral 4748. When using, a thin-walled flexibletube, the tube is inserted into the hole and is held into place byfriction and/or adhesive. The hole may be expanded during insertion toaid in installation. Possible flexible tube with flange materialsinclude gel, silicone, rubber, latex, polymers or a flexible duct hose.The sealant or flange(s) 4746 and 4748 add impermeability to theunderside and the top of the mattress, respectively.

Turning to FIG. 47B (sealant, or flexible insert with a flange andsealant), shown is a sealant system 4750 with foam comfort layers 4752adjacent to a sealed angled hole 4754. The hole 4744 is sealed either bya sealant or via an insert as described above. The sealant system 4750also includes flanges or sealant that extend across the top and bottomsurfaces of the mattress, to extend the sealed areas around the hole(s).In the figure, the bottom flange or sealant is identified by referencenumeral 4756 and the top flange or sealant is identified by referencenumeral 4758. When using, a thin-walled flexible tube, the tube isinserted into the hole and is held into place by friction and/oradhesive. The hole may be expanded during insertion to aid ininstallation. Possible flexible tube with flange materials include gel,silicone, rubber, latex, polymers or a flexible duct hose. The sealantor flange(s) 4756 and 4758 add impermeability to the underside and thetop of the mattress, respectively.

FIGS. 48A and 48B show an additional embodiment of sealed vertical holesor slots in a mattress. Turning to FIG. 48A (a vertical insert), shownis a sealant system 4840 with foam comfort layers 4842 adjacent to avertically oriented insert 4849, which may be constructed from polymersrubber, fabric or foam, such as reticulated foam. The outer surface 4844of the insert 4849 is made impermeable by an impermeable fabric,polymer, or applied flexible sealant. Alternatively, the insert 4849 isplaced within the flexible impermeable tube, of the type describedabove. The sealant system 4840 may also include optional flanges orsealant that extend across the top and bottom surfaces of the mattress,to extend the sealed areas around the holes. In the figure, the bottomflange or sealant is identified by reference numeral 4846 and the topflange or sealant is identified by reference numeral 4848. The sealantor flange(s) 4746 and 4748 add impermeability to the underside and thetop of the mattress, respectively.

Turning to FIG. 48B (an angled insert), shown is a sealant system 4850with foam comfort layers 4852 adjacent to an angularly oriented insert4859, which may be constructed from polymers rubber, fabric or foam,such as reticulated foam. The outer surface 4854 of the insert 4859 ismade impermeable by an impermeable fabric, polymer, or applied flexiblesealant. Alternatively, the insert 4859 is placed within the flexibleimpermeable tube, of the type described above. The sealant system 4850may also include optional flanges or sealant that extend across the topand bottom surfaces of the mattress, to extend the sealed areas aroundthe holes. In the figure, the bottom flange or sealant is identified byreference numeral 4856 and the top flange or sealant is identified byreference numeral 4858. The sealant or flange(s) 4756 and 4758 addimpermeability to the underside and the top of the mattress,respectively.

FIGS. 49A and 49B show an additional embodiment of sealed vertical holesor slots in a mattress. Turning to FIG. 49A (a vertical insert orapplied sealant, with an additional layer), shown is a sealant system4940 with foam comfort layers 4942 adjacent to a vertically orientedinsert 4944, which may be constructed from polymers rubber, fabric, orfoam, such as reticulated foam. The sealant system 4840 includes flangesor sealant that extend across the top and bottom surfaces of the foamcomfort core layers, to extend the sealed areas around the holes. In thefigure, the bottom flange or sealant is identified by reference numeral4946 and the top flange or sealant is identified by reference numeral4948. Each of the flanges or sealant 4946 and 4948 is secured by anadditional layer 4947 and 4949, respectively, that is added to the topand/or bottom of the foam comfort core. The additional layer has holesin it to match the holes that run through the comfort core layers. Theadditional layer may be made from a permeable, semi-permeable, orimpermeable material.

Turning to FIG. 49B (an angled insert or applied sealant, with anadditional layer), shown is a sealant system 4950 with foam comfortlayers 4952 adjacent to an angularly oriented insert 4954, which may beconstructed from polymers rubber, fabric, or foam, such as reticulatedfoam. The sealant system 4840 includes flanges or sealant that extendacross the top and bottom surfaces of the foam comfort core layers, toextend the sealed areas around the holes. In the figure, the bottomflange or sealant is identified by reference numeral 4956 and the topflange or sealant is identified by reference numeral 4958. Each of theflanges or sealant 4956 and 4958 is secured by an additional layer 4957and 4959, respectively, that is added to the top and/or bottom of thefoam comfort core. The additional layer has holes in it to match theholes that run through the comfort core layers. The additional layer maybe made from a permeable, semi-permeable, or impermeable material.

FIGS. 50A and 50B show an additional embodiment of sealed vertical holesor slots in a mattress. Here, to maintain better support to a user, theholes through the foam comfort core layers are made relatively small.Turning to FIG. 50A (vertical insert or applied sealant with anadditional layer), shown a sealant system 5040 with foam comfort layers5042 adjacent to a vertically oriented insert 5044. Flanges or sealantextend across the bottom face 5046 and the top face 5048 to extend thesealed areas around the hole(s). An additional top layer 5049 and anadditional bottom layer 5047, each having a hole of larger diameter thenthe hole through the comfort-core layers, are added to the top andbottom, respectively. Due to the larger hole diameter in theseadditional top and bottom layers, the area available to air passingthrough the hole at the top and bottom surfaces is larger than that ofthe hole through the foam comfort core layers 5042. As a result, airpassing through the fabric that is in contact with the top and bottom ofthe foam core layers has a larger area to pass through and thereforereduces resistance loss.

Turning to FIG. 50B (angular insert or applied sealant with anadditional layer), shown a sealant system 5050 with foam comfort layers5052 adjacent to an angularly oriented insert 5054. Flanges or sealantextend across the bottom face 5056 and the bottom face 5048 to extendthe sealed areas around the hole(s). An additional top layer 5059 and anadditional bottom layer 5057, each having a hole of larger diameter thenthe hole through the comfort-core layers, are added to the top andbottom, respectively. Due to the larger hole diameter in theseadditional top and bottom layers, the area available to air passingthrough the hole at the top and bottom surfaces is larger than that ofthe hole through the foam comfort layers 5052. As a result, air passingthrough the fabric that is in contact with the top and bottom of thefoam comfort layers has a larger area to pass through and thereforereduces resistance loss.

FIG. 51 shows the cross-section and top views of a mattress system usinginserts with holes or slots. In this embodiment, the assembly 5100includes comfort layers 5102 with two rows of openings 5104 (e.g.,pill-shaped slots). Inserts 5106 with dual holes 5108 are located withinthe slotted openings 5104. Note, the number of rows of slotted openingsin the comfort layers and the number of holes 5108, and their layout, ineach insert 5106 could be varied. The inserts 5106, which are assembledinto the openings 5104, may be formed from molded or machined pieces offoam that incorporate holes through them. The inserted pieces could bemolded from self-skinning foam, or have their surfaces sealed in otherways, for example spraying with a liquid sealant. The holes in theinserts can be of various shape, sizes, and angles. For example, in someembodiments the angle could be such that one could see all the way downthrough the hole when looking from above the insert. In otherembodiments, the angle could be large enough such that one could not seeall the way down through the hole when looking from above the insert.

FIGS. 52A, 52B, 52C, 52D, 52E, and 52F show various embodiments of theinserts in FIG. 51. Turning to FIG. 52A, shown is an insert 5200 withtwo angularly running holes 5202 with sealed surfaces. The topmostportion of the figure shows a cross-section of the insert 5200. The nextportion down in the FIG. 52A depicts the insert from the bottom, alongsection A-A. Right below, FIG. 52A shows two side views of the insert5200, from different directions. Finally, the lowest portion of thefigure depicts the view of the insert from the top.

Turning to FIG. 52B, shown is a two-part insert 5220 having twoangularly running holes 5222 with sealed surfaces. The two parts,constituting two halves of the insert, are joined together to form theinsert. The topmost portion of the figure shows a cross-section of theinsert 5220. The next portion down in the FIG. 52B depicts one half ofthe insert, when viewed from the bottom. Right below, FIG. 52A shows twoside views of the insert 5220, from different directions. Right belowthat, FIG. 52B shows one half of the insert, viewed from the top.Finally, the lowest portion of the figure depicts the two halves of theinsert joined together 5226, forming the insert, viewed from the bottom.

Turning to FIG. 52C, shown is an insert 5230 with two angularly runningholes 5232 with sealed surfaces. The topmost portion of the figure showsa cross-section of the insert 5230. As can be seen from thecross-sectional view, each hole changes its angle as it passes throughthe insert. The next portion down in the FIG. 52C depicts the insertfrom the bottom, along section A-A. Right below, FIG. 52C shows two sideviews of the insert 5230, from different directions. Finally, the lowestportion of the figure depicts the view of the insert from the top.

Turning to FIG. 52D, shown is a cross-sectional view of an insert 5240with a single hole having a conical shape. Turning to FIG. 52E, shown isa cross-sectional view of an insert 5250 with a single hole having acircular shape. Turning to FIG. 52F, shown is a cross-sectional view ofan insert 5260 with a single hole having a circular shape that isnarrower than in FIG. 52E, but that flares out at top and bottom of theinsert. In each of the embodiments, the surfaces of the holes are sealedto prevent air loss.

FIG. 53 shows another embodiment of the mattress system using insertswith holes or slots. The upper portion of FIG. 53 shows the top view ofthe mattress system and the lower portion of the figure shows across-sectional view of the mattress system along section A-A. From thetop view, one can see the mattress system 5300 includes five sections,5301 a, 5301 b, 5301 c, 5301 d, and 5301 e. Sections 5301 b and 5301 dare molded or machined insert sections that are assembled in between thesections 5301 a, 5301 c, and 5301 e of regular foam comfort layers. Theinsert sections have holes running through them. These holes can havevarious shapes, e.g., circles, squares, rectangles, etc. and may bevertical or angled. The cross-sectional view of the mattress system atthe bottom of FIG. 53 shows an angular hole 5304 in the insert 5301 band also shows an angular hole 5306 in the insert 5301 d. The foamcomfort layers are designated by reference numeral 5302.

FIG. 54 shows an embodiment of the mattress system 5400 using insertsfor forming holes or slots in the system. The upper portion of FIG. 54shows the top view of the mattress system and the lower portion of thefigure shows a cross-sectional view of the mattress system along sectionA-A. This embodiment differs from the embodiment in FIG. 53 in that themolded or machined insert-sections 5402 and 5404 are assembled incutouts in the regular foam comfort layers 5406. Once installed, theinserts form one side of each hole. The cross-sectional view of themattress system at the bottom of FIG. 53 shows an angular hole formed bythe combination of the insert 5404 and the comfort layers 5406. Theseholes can have various shapes, e.g., circles, squares, rectangles, etc.and may be vertical or angled. Sealing may be achieved by employing aself-skinning molded foam for the insert, or by applying a liquidsealant to a permeable foam or foam layers.

FIG. 55 shows another embodiment of the mattress system 5500 with holesor slots. The upper portion of FIG. 55 shows the top view of themattress system and the lower portion of the figure shows across-sectional view of the mattress system along section A-A. From thetop view, one can see the mattress system 5500 includes five sections,5501 a, 5501 b, 5501 c, 5501 d, and 5501 e, of comfort layers that areeither cut along cut lines 5504 and separated or are formed along cutlines 5504. The cut face(s) of each of the five sections, along theline(s) 5504, is then sealed. Sealing may be achieved by, for example,applying liquid sealant to the cut faces, or laminating an impermeablemembrane to the cut faces. The sections are then assembled together,forming sealed vertical or angled holes withing the mattress system5500. The holes can have various shapes, e.g., circles, squares,rectangles, triangular, etc. The cross-sectional view of the mattresssystem 5500 at the bottom of FIG. 55 shows the angular holes formed inthe comfort layers 5502.

FIG. 56 shows another embodiment of a mattress system with verticalholes or slots. The left side of FIG. 56 shows a cross-sectional view ofthe mattress system and the right side of the figure shows a top view ofthe mattress system. As can be seen from the cross-sectional view, themattress system 5600 is composed of seven layers (labeled L1 throughL7), with L1 being the topmost layer and L7 being the bottommost layer.The cross-sectional view also shows two holes 5602 and 5604 cut throughthe layers. Hole 5602 is located in the middle of the mattress (torsozone) and hole 5604 is located at the right end of the mattress (footzone). In this embodiment, some of the mattress layers include multiplesections of different materials, having different densities and ILDcharacteristics, or may include similar materials having differentcharacteristics. For example, the topmost (first) layer L1 includes twosections, left and right. In one preferred embodiment, the left sectioncould be hypersoft foam, labeled in the figure as L1A, and the leftsection could be viscoelastic foam, labeled as L1B. The third layerdown, L3, for example, includes three sections (left, middle, andright). In one embodiment, the middle section could be hypersoft foamhaving one set of characteristics (labeled L3B), and the right and leftsections could be hypersoft foam having another set of characteristics(labeled L3A). Some of the materials that may be used in the variouslayers include hypersoft foam, viscoelastic foam, high resiliency foam,convoluted foam, and rubber.

Looking at the top view of the mattress system 5600 (right side of FIG.56), one can see the two sections of the first layer L1. The top viewalso shows that the holes 5602 and 5604 have an oval slotted shape. Eachrow of holes running across the mattress is further divided into twogroups (left and right), allowing the mattress system 5600 toaccommodate two occupants.

FIGS. 57A, 57B, 57C, and 57D show an embodiment of a seven-layermattress system that uses tubular inserts. FIG. 57A shows a top view ofthe mattress system 5700, with two rows of oval-shaped holes (slots)5702 and 5704. FIG. 57B shows a cross-sectional view of the mattresssystem 5700 along the line A-A in FIG. 57A, illustrating the row ofholes 5704 across the mattress. FIG. 57C shows a detailed view of themattress system 5700 in area B of FIG. 57B. Specifically, FIG. 57C showstwo holes, one labeled 5704 a and another labeled 5704 b, each passingthrough the seven layers of the mattress system 5700. A plastic (orrubber) insert 5706 is placed in each hole. The insert includes flangeson top and bottom. Importantly, the flanges do not protrude all the wayto the top and/or bottom of the mattress system 5700. Instead, the topmattress layer covers up the upper flanges from the top and the bottommattress layer covers up the lower flanges from the bottom. This way,the upper flange of each insert is secured between the first and secondmattress layers and the lower flange of each insert is secured betweenthe sixth and seventh mattress layers. Such a construction not onlyprevents the inserts from separating from the mattress layers, but alsoprovides aesthetically pleasing design, as the insert flanges are notvisible to the user. In the preferred embodiment, the inserts have anaccordion type design, which allows them to contract and expand togetherwith the mattress layers in response to the different forces applied tothe mattress system 5700 by the occupants.

FIG. 57D shows a cross-sectional view of the mattress system along theline C-C in FIG. 57A. It depicts the inserts 5706 in the hole(s) 5702 inthe middle of the mattress (torso zone) and in the hole(s) 5704 at oneend of the mattress (foot section). Similar to the mattress system 5600in FIG. 56, the cross-sectional view of mattress system 5700 in FIG. 57Dshows the mattress layers having various sections of various materials.

FIGS. 58A, 58B, and 58C show cross-sectional views of another set ofembodiments of a mattress system with holes or slots. Similar to themattress system 5600 in FIG. 56, the cross-sectional views in FIGS. 58A,58B, and 58C show seven-layer mattress systems where some of the layersare composed of various sections of different material.

Turning to FIG. 58A, shown is a cross-sectional view of a seven-layermattress system 5800 with vertically placed rubber inserts 5802.

Turning to FIG. 58B, shown is a cross-sectional view of a seven-layermattress system 5810 with rubber inserts 5814 placed in the holes 5816and 5818 that are running at a slight angle. At the angle shown in FIG.58B, when looking straight down from above the insert 5814, one can seeall the way through the hole to the bottom of the mattress.

Turning to FIG. 58C, shown is a cross-sectional view of a seven-layermattress system 5820 with rubber inserts 5824 placed in the holes 5826and 5828 that are running at a greater angle then the one in FIG. 58B.At the angle shown in FIG. 58C, when looking straight down from abovethe insert 5824, one cannot see all the way through the hole to thebottom of the mattress.

FIGS. 59A, 59B, and 59C show cross-sectional views of another set ofembodiments of a mattress system with holes or slots. Similar to themattress systems in FIGS. 58A, 58B, and 58C the cross-sectional views inFIGS. 59A, 59B, and 59C also show seven-layer mattress systems, 5900,5910, and 5920 respectively, where some of the layers are composed ofvarious sections of different materials. In contrast to the embodimentsin FIGS. 58A, 58B, and 58C, however, the inserts 5902, 5912, and 5922 inthe FIGS. 59A, 59B, and 59C, respectively, are molded pneumatic insertsthat, when inserted, span layers two (L2) through six (L6) in both thetorso and foot zones of the mattress system. The top and bottom layers(L1 and L7) have holes that line up with the holes in the inserts. InFIG. 59A, the holes in the insert 5902 run vertically; in FIG. 59B, theholes in the inserts 5912 run at a slight angle off vertical; and inFIG. 59C, the holes in the inserts 5922 run at a greater angle offvertical, such that when looking straight down from above the insert,one cannot see all the way through the hole to the bottom of themattress. Because the walls of each hole should be substantiallyimpermeable to air, the inserts 5902, 5912, and 5922 should either bemade of substantially impermeable material, self-skinning foam, or haveliquid sealant applied to them.

FIGS. 60A and 60B show cross-sectional views of another set ofembodiments of a mattress system with holes or slots. Similar to themattress systems in FIGS. 59A and 5B, the cross-sectional views in FIGS.60A and 60B also show seven-layer mattress systems, 6000 and 6010respectively, where some of the layers are composed of various sectionsof different materials. In contrast to the embodiments in FIGS. 59A and59B, however, the inserts 6002 and 6012 in the FIGS. 60A and 60B,respectively, are pneumatic fabricated die cut inserts, which, wheninserted, span layers two (L2) through six (L6) in both the torso andfoot zones of the mattress system. The top and bottom layers (L1 and L7)have holes that line up with the holes in the inserts. In FIG. 60A, thehole in the insert 6002 runs vertically; and in FIG. 60B, the hole inthe insert 6012 runs at an angle. Because each insert is made up ofstacked, die cut material layers, the angularly running hole in theinsert 6012 appears to have stepped edges. Because the walls of eachhole should be substantially impermeable to air, the inserts 6002, and6012 should either be made of substantially impermeable material(s),self-skinning foam(s), or have liquid sealant applied to them.

FIGS. 61A, 61B, and 61C show cross-sectional views of another set ofembodiments of a mattress system with holes. Similar to the mattresssystems in FIGS. 59A, 58B, and 58C the cross-sectional views in FIGS.61A, 61B, and 61C also show seven-layer mattress systems, 6100, 6110,and 6120 respectively, where some of the layers are composed of varioussections of various materials. In contrast to the embodiments in FIGS.59A, 59B, and 59C, however, the mattress systems in the FIGS. 59A, 59B,and 59C include inserts drilled holes. In FIG. 61A, the holes 6102 aredrilled vertically; in FIG. 61B, the holes are drilled at a slight angleoff vertical; and in FIG. 61C, the holes are drilled at a greater angleoff vertical, such that when looking straight down from above a hole,one cannot see all the way through it to the bottom of the mattress.Because the walls of each hole should be substantially impermeable toair the material in the sections of the layers where the holes arelocations should either be made of substantially impermeable material,self-skinning foam, or have liquid sealant applied to them.

Each of the methods of sealing the hole walls discussed above can beapplied to holes that are angled along their axis, and of anycross-section, e.g., circular, elliptical, rectangular, square, etc. Forexample, FIGS. 46A, 46B, and 46C, which correspond to FIGS. 39D, 39E,and 39F, respectively, show holes that are angled along their axis.

In addition, the various insert embodiments may be used interchangeablyor in combinations to achieve the required airflow in the mattress.

As an example, the invented mattress may include a laterally extendingcomfort layer, which itself may include a plurality of layers, saidcomfort layer having a lower surface and an upper surface, said comfortlayer comprising an opening extending through said comfort layer fromthe upper surface to the lower surface; a tubular insert positionedwithin the opening of said comfort layer and having an upper end and alower end, said tubular insert having an air-impermeable peripheral wallextending between the upper end and the lower end of said tubularinsert, said tubular insert further comprising a first air-impermeableflange located at one of the upper end and the lower end of said tubularinsert and extending around the opening at one of the upper surface andthe lower surface of said comfort layer; a laterally extending bottomlayer joined to the lower surface of said comfort layer, said bottomlayer having an aperture that is aligned with the opening at the lowersurface of said comfort layer, the aperture being equal to or greaterthan the opening at the lower surface of said comfort layer; a laterallyextending top layer joined to the upper surface of said comfort layerand having an aperture that is aligned with the opening at the uppersurface of said comfort layer, the aperture being equal to or greaterthan the opening at the upper surface of said comfort layer; wherein oneof said top layer and said bottom layer secures said first flange ofsaid tubular insert to said comfort layer. The tubular insert maycomprise a second air-impermeable flange located at the other one of theupper end and the lower end of said tubular insert, said second flangeextending round the opening at the other one of the upper surface ofsaid comfort layer and the lower surface of said comfort layer; andwherein the other one of said top layer and said bottom layer securessaid second flange of said tubular insert to said comfort layer.

As another example, the invented mattress system may include a pluralityof laterally extending foam layers joined together, said plurality offoam layers having an upper surface and a lower surface, said pluralityof foam layers further having at least one opening extending between theupper surface and the lower surface of said plurality of foam layers; anat least one foam insert positioned within said at least one opening,said at least one foam insert having an upper surface and a lowersurface, said at least one foam insert further comprising a hole runningfrom the upper surface of said at least one foam insert to the lowersurface of said at least one foam insert; and a fan located below saidplurality of foam layers, said fan configured to force air through thehole in said foam insert toward the upper surface of said foam insert;wherein the interior surface of said hole in the foam insert inair-impermeable; wherein the upper surface of said at least one foaminsert is aligned with the upper surface of said plurality of laterallyextending foam layers; and wherein the lower surface of said at leastone foam insert is aligned with the lower surface of said plurality oflaterally extending foam layers. The interior surface of the foam insertmay be made air-impermeable due to self-skinning property of the foaminsert, such as use of a foam having self-skinning property.Alternatively, the interior surface of the foam insert may be madeair-impermeable by applying a sealant.

As another example, the invented mattress system may include a pluralityof laterally extending foam layers joined together, said plurality offoam layers having an at least one opening therethrough, said openinglocated in a torso zone of said mattress; a foam insert positionedwithing the opening, said foam insert comprising a hole therethrough forallowing airflow between a top surface of said mattress and a bottomsurface of said mattress; wherein the interior surface of said hole inair-impermeable; and wherein said foam insert increases support in thetorso zone of said mattress.

As a result, the invented insert not only functions to allow airflowfrom the bottom to the top of the mattress, but it also functions as asupport element. Because the invented inserts may be placed in areasother than the torso zone of the mattress (e.g., foot section, hipsection, shoulder section, head section, etc.), the present inventionallows for mattress designs that are not only provide better temperatureregulation but are optimized to provide increased support to a userhuman anatomy. The foam inserts disclosed above may not have any airholes but could be used merely for providing specific localized supportin and across the various mattress zones. For example, foam inserts inthe torso zone might provide greater support then the foam inserts inthe foot zone. In addition, insert provided support could also varyacross a single zone.

The invented foam insert may be formed by molding or by died cutting.For example, an insert including a plurality of die cut layers may haveits hole created by a stacked combination of the holes die cut in eachof the layers. In such a situation, if the insert hole is either slantedor has a cross-sectional area that varies from the bottom to the top ofthe insert, the interior surface of the resulting hole will have astepped profile.

FIGS. 40A, 40B and 40C show various constructions that improve airflowthroughout a mattress system. They may be used singly or in combination.

Turning to FIG. 40A, shown is a partial mattress system cross-section3960 where a mattress 3961 includes a plurality of vertical cutouts3962. A specially formed EPP segment 3966 has a raised edge thatincreases the pressure around the duct outlet perimeter. This compressesthe bottom foam layer 3963 and creates a better seal between the baselayer and the mattress. Another portion of the EPP segment 3965(partially shown) also compresses the bottom foam layer 3963. Theblower/heater combination 3964 may be inserted into the EPP segment aswell to complete construction of the base layer interfacing with themattress.

Turning to FIG. 40B, shown is a partial mattress system cross-section3970 with a frame 3972 installed at the bottom of the foam layers. Asshown in the inset 3971 on the top left, the frame 3972 incorporatesholes that lets air through from the base layer to the mattress layer.The holes in the frame 3972 may “match up” with the holes in themattress. Alternatively, the frame 3972 may have only edges with an openmiddle. The frame edges 3974 a, 3974 b may consist of impermeable butflexible material (such as EPP) that solidifies the installation of theframe 3972 within the mattress.

One purpose of the frame 3972 is to create air space between themattress cover 3973 and the underside of the foam 3975. This increasesarea that the air can flow through the mattress cover 3973 which resultsin lower pressure drop and less losses in flow.

Turning to FIG. 40C, shown is a partial mattress cross-section 3990 witha mattress having vertical air passages 3994 a, 3994 b, 3994 c, 3994 dtaking air blown from airboxes 3992 a, 3992 b through ducts 3991 a, 3991b. Underneath the airboxes 3992 a, 3992 b and their related EPP segments(not shown) is a permeable base cover (also not shown) that allows theair to be drawn in by the airboxes 3992 a, 3992 b. Surrounding themattress on the top and the sides is a permeable mattress cover (notshown) that allows the air to be pushed out through the vertical airpassages 3994 a, 3994 b, 3994 c, 3994 d. In contrast, portions of thetop of the base layer and the bottom of the mattress layer 3993 a, 3993b and 3993 c may be made of an impermeable material such as rubberhaving lamination. This material improves airflow throughout themattress by maximizing the amount of air drawn in by the airboxes 3992a, 3992 b actually passing through ducts 3991 a, 3991 b.

VIII. Remote

The scope and functionality of remotes to allow the user to controlfeatures within a temperature-regulating mattress system is describedherein. The purpose of these remotes includes allowing users to makereal-time adjustments to mattress parameters without the user having toget out of bed. This is especially useful when the user wants to make anadjustment in the midst of a sleep cycle.

The properties of the remote discussed herein may be mixed and varied asneeded to provide various functions for the mattress system.

In addition to these remotes, an app may be used to control similarfeatures of the mattress in addition to providing an interface for morecomplex operations (such as those described above in FIG. 4B).

Turning to FIG. 41A, shown is a schematic of a remote 4000 for amattress system. The remote 4000 is generally puck-shaped andincorporates a full surface tactile button 4002 and is capable ofrecognizing gesture sensing 4004 performed on the remote 4000. Theremote 4000 is capable of rotations 4006 and has a haptic motor 4012.Alight indicator 4010 is installed on the top of the remote 4000. Agradient light indicator 4014 emanates from the bottom of the remote4000. Installed on the bottom of the remote 4000 is a reset button 4008and LED 4016.

Turning to FIG. 41B, shown is a cross-section of the remote in FIG. 41Aintegrated with its base 4100 and a cross-section of the remoteseparated from its base 4110. The rotating member 4112 is selectivelyseparable and attachable from its base 4114 to allow for battery access.

Turning to FIG. 41C, shown is an exploded view 4150 of the remote inFIG. 41A. Moving from top to bottom, shown is a dial top 4152, a linearresonant actuator/haptic motor 4154, capacitive touch sensor 4156, a PCB4158, a light pipe/diffuser 4160, a battery housing 4162, batteries4164, a rotating plate 4166, a bearing 4168 and a base with rubber grip4170.

The PCB 4158 may contain an internal management unit, accelerometer orgyroscope.

FIGS. 42, 43, 44 and 45 show schematics of alternative remotes formattress system.

Turning to FIG. 42, shown is a schematic of a log-shaped remote system4200. This log-shaped remote system 4200 includes a touch and presssurface 4210, an emanating light 4220 and a re-charging port door 4230.

Turning to FIG. 43, shown is a schematic of a flip-over remote system4300. On the left, the remote 4310 is in profile mode. Here the profilemode may show the remote is in standby mode (represented by Z's in onecolor). A press on the remote 4320 may be used by a user to cyclebetween desired features and a twist of the remote 4330 may increase ordecrease the temperature, airflow or other feature parameter. Whenactivated the color of the Z's may change, telling the user that thestatus of the remote or parameter has changed.

The remote may be flipped 4340 to enter basic mode 4350. Here a pressmay turn the remote on or off 4360 and a twist 4370 may activate oradjust various features in the mattress system.

Turning to FIG. 44, shown is a schematic of a bounce-back remote system4400. This remote is constructed so a left or right twist of the dialalways springs back to the center. A press 4410 on the remote may startthe system. A twist 4420 on the remote may adjust various systemparameters. A double press 4430 on the remote may pause the system.Along press 4440 (such as 3 seconds) may turn the system off.

Turning to FIG. 45, shown is a remote horizontal gesture system 4510 anda remote vertical gesture system 4520 that may control features of amattress system. The gesture sensing module in the remote detectsmid-air horizontal and vertical gestures.

IX. Conclusion

In the foregoing specification, specific embodiments have beendescribed. However, one of ordinary skill in the art appreciates thatvarious modifications and changes can be made without departing from thescope of the invention as set forth in the claims below. Accordingly,the specification and figures are to be regarded in an illustrativerather than a restrictive sense, and all such modifications are intendedto be included within the scope of present teachings.

The benefits, advantages, solutions to problems, and any element(s) thatmay cause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeatures or elements of any or all the claims. The invention is definedsolely by the appended claims including any amendments made during thependency of this application and all equivalents of those claims asissued.

Moreover, in this document, relational terms such as first and second,top and bottom, and the like may be used solely to distinguish oneentity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions. The terms “comprises,” “comprising,” “has”,“having,” “includes”, “including,” “contains”, “containing” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises, has,includes, contains a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. An element proceeded by“comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . .a” does not, without more constraints, preclude the existence ofadditional identical elements in the process, method, article, orapparatus that comprises, has, includes, contains the element. The terms“a” and “an” are defined as one or more unless explicitly statedotherwise herein. The terms “substantially”, “essentially”,“approximately”, “about” or any other version thereof, are defined asbeing close to as understood by one of ordinary skill in the art. Theterm “coupled” as used herein is defined as connected, although notnecessarily directly and not necessarily mechanically. A device orstructure that is “configured” in a certain way is configured in atleast that way but may also be configured in ways that are not listed.

The Abstract of the Disclosure is provided to allow the reader toquickly ascertain the nature of the technical disclosure. It issubmitted with the understanding that it will not be used to interpretor limit the scope or meaning of the claims. In addition, in theforegoing Detailed Description, various features are grouped together invarious embodiments for streamlining the disclosure. This method ofdisclosure is not to be interpreted as reflecting an intention that theclaimed embodiments require more features than are expressly recited ineach claim. Rather, as the following claims reflect, inventive subjectmatter lies in less than all features of a single disclosed embodiment.Thus, the following claims are hereby incorporated into the DetailedDescription, with each claim standing on its own as a separately claimedsubject matter.

We claim:
 1. A mattress system comprising: a laterally extending comfortlayer having a lower surface and an upper surface, said comfort layercomprising an opening extending through said comfort layer from theupper surface to the lower surface; a tubular insert positioned withinthe opening of said comfort layer and having an upper end and a lowerend, said tubular insert having an air-impermeable peripheral wallextending between the upper end and the lower end of said tubularinsert, said tubular insert further comprising a first air-impermeableflange located at one of the upper end and the lower end of said tubularinsert and extending around the opening at one of the upper surface andthe lower surface of said comfort layer; a laterally extending bottomlayer joined to the lower surface of said comfort layer, said bottomlayer having an aperture that is aligned with the opening at the lowersurface of said comfort layer, the aperture being equal to or greaterthan the opening at the lower surface of said comfort layer; a laterallyextending top layer joined to the upper surface of said comfort layerand having an aperture that is aligned with the opening at the uppersurface of said comfort layer, the aperture being equal to or greaterthan the opening at the upper surface of said comfort layer; wherein oneof said top layer and said bottom layer secures said first flange ofsaid tubular insert to said comfort layer.
 2. The mattress system ofclaim 1, wherein said tubular insert comprises a second air-impermeableflange located at the other one of the upper end and the lower end ofsaid tubular insert, said second flange extending round the opening atthe other one of the upper surface of said comfort layer and the lowersurface of said comfort layer; and wherein the other one of said toplayer and said bottom layer secures said second flange of said tubularinsert to said comfort layer.
 3. The mattress system of claim 1, whereinsaid laterally extending comfort layer comprises a plurality of layers.4. The mattress system of claim 1, wherein the opening in said comfortlayer is vertical.
 5. The mattress system of claim 1, wherein theopening in said comfort layer is slanted.
 6. The mattress system ofclaim 1, wherein said tubular insert comprises an encapsulated coilspring.
 7. The mattress system of claim 1, wherein said air-impermeableperipheral wall of said tubular insert is accordion shaped, to allow forcontraction and expansion of said tubular insert in response to changesin vertical loading on said insert.
 8. A mattress system comprising: aplurality of laterally extending foam layers joined together, saidplurality of foam layers having an upper surface and a lower surface,said plurality of foam layers further having at least one openingextending between the upper surface and the lower surface of saidplurality of foam layers; an at least one foam insert positioned withinsaid at least one opening, said at least one foam insert having an uppersurface and a lower surface, said at least one foam insert furthercomprising a hole running from the upper surface of said at least onefoam insert to the lower surface of said at least one foam insert; and afan located below said plurality of foam layers, said fan configured toforce air through the hole in said foam insert toward the upper surfaceof said foam insert; wherein the interior surface of said hole in thefoam insert is air-impermeable; wherein the upper surface of said atleast one foam insert is aligned with the upper surface of saidplurality of laterally extending foam layers; and wherein the lowersurface of said at least one foam insert is aligned with the lowersurface of said plurality of laterally extending foam layers.
 9. Themattress system of claim 8, wherein the interior surface of said foaminsert is air-impermeable due to a self-skinning property of said foaminsert.
 10. The mattress system of claim 8, wherein the interior surfaceof said foam insert is air-impermeable due to a sealant applied to theinterior surface.
 11. The mattress system of claim 8, wherein the holein said foam insert is vertical.
 12. The mattress system of claim 8,wherein the hole in said foam insert is slanted.
 13. The mattress systemof claim 8, further including a thermal conditioning element positionedbetween said fan and said foam insert, said thermal conditioning elementenabling thermal conditioning of the air forced by said fan through thehole in said foam insert.
 14. A mattress comprising: a plurality oflaterally extending foam layers joined together, said plurality of foamlayers having an at least one opening therethrough, said opening locatedin a torso zone of said mattress; a foam insert positioned withing theopening, said foam insert comprising a hole therethrough for allowingairflow between a top surface of said mattress and a bottom surface ofsaid mattress; wherein the interior surface of said hole inair-impermeable; and wherein said foam insert increases support in thetorso zone of said mattress.
 15. The mattress system of claim 14,wherein the interior surface of said foam insert is air-impermeable dueto a self-skinning property of said foam insert.
 16. The mattress systemof claim 14, wherein the interior surface of said foam insert isair-impermeable due to an applied sealant.
 17. The mattress system ofclaim 14, wherein the hole in said foam insert is vertical.
 18. Themattress system of claim 14, wherein the hole in said foam insert isslanted.
 19. The mattress in claim 14, wherein said foam insert ismolded.
 20. The mattress in claim 14, wherein said foam insert comprisesa plurality of stacked die cut foam layers.